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Nest on my list of things to wrap up is to run the supply and return lines for the fuel injection on the 61. First question: I can go with Nylon plastic or high pressure rubber fuel lines. With nylon lines you heat the ends and slide them over the barbed fittings. With rubber you use hose clamps. I am thinking of going with rubber simply because they can probably withstand the odd stone better. Thoughts?
Second question: I have been doing some research on size of lines. Consensus seems to be 3/8" supply, 5/16" return line. The thing is...all of the factory fittings have 1/4'' openings. So the way I see it, you can have as large as a hose you want, there is only a 1/4' hole in the fittings for the fuel to run thru. So, I'm thinking all I need is 1/4" inside diameter line for both supply and return and I will be good to go. It's a stock 4.6, I can't see the need for larger diameter line? What is confusing however,on the Crown Vic, at the fuel rail both supply and return lines were 1/4" Nylon lines protected by a rubber hose. The supply line off of the fuel pump/sending unit assembly was a larger stainless steel braided larger line I'm guessing 3/8". The return line at the tank was also braided stainless steel. Why use stainless at the tank and why larger line for the supply when all fittings were 1/4" inside diameter?
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I have used the Nylon line however mine was covered in braided stainless. I used it for my hydroboost unit. The ends were easy enough to put on and over all it was fantastic stuff however there is not a lot flex in it this can make sharper corners and over all fitment a little more challenging. I still think I would use the Nylon over the rubber. I don't think 1/4" fittings will limit the flow that much especially since it is a pressurized system. Limiting the entire thing to 1/4" is however IMHO not the best idea. It will probably work fine but it will cause the pump to work harder As to your return line why not use the fuel line the car came with??
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The way I see it, I can't go with anything other than 1/4" I.D. hose because all of the connectors(I called them fittings) are 1/4" with the the exception of one, that being the one connecting the supply line to the tank. Even both inlet and outlet on the fuel filter are 1/4". I would go with a larger line if I could just don't know how that could be possible with 1/4" connectors?
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